Float for steam traps and the like and method of making same



Am-ii 29, 1924.

' 11,492,349 J. R. BROWN ET AL FLOAT FOR STEAM TRAPS AND THE LIKE AND METHOD OF MAKING SAME Filed Feb. 8. 1922 a RN 1 INVENTORL Il Jbzz Bow/and 51 0 22 and 6 1 BY 1572.21 CfZfZa/fznzzzlr.

ATTORNE A9 Patented Apr. 29, 1924.

JOHN ROWLAND BROWN AND JOHN C. MULLINNIX, OF CLEVELAND, OHIO, ASSIGNOP'S TO THE RELIANCE GAUGE COLUMN COMPANY, OF CLEVELAND, OHIO, A CORPORA- TION OF OHIO.

FLOAT FOR STEAM TRAPS AND THE LIKE AND METHOD OF MAKING SAME.

Application filed February 8, 1922. Serial No. 535,037.

To all whom it may concern:

Be it known that we, JOHN ROWLAND Brown and JOHN C. MULLINNIX, citizens of the United States, and residents of Cleveland, county of Guyahoga, State of Ohio,

have jointly invented a new and useful Improvcment in Floats for Steam Traps and the like and Methods of Making Same, of which the following is a specification, the

' principle of the invention being herein explained and the best mode in which we have contemplated applying that principle, so as to distinguish it from other inventions.

The present improvements relate more particularly to floats composed of a hollow foundation and an external seamless metallic shell or coating formed by electro-plating such foundation instead of spinning such floats from sheet metal (usually copper) in hemispheres and then lapping together and brazing the two sections at the joint. The latter has continued'to be the commercial method of manufacture of such floats despite the fact that the electro-plating art long ago reached a high point of development and despite the fact that inventors have from time to time suggested the possibility of employing the method of electro plating to the making of articles of the type in hand, see for example, U. S. Patent No. 256,270 to P. Barker, dated April 11, 1882, and No. 691,803 to W. F. Patton, dated J anuary 28, 1902. It is not, however, as simplea matter as has apparently been supposed to electro-deposit copper, or other metal, on such an internal hollow foundation and secure a uniform coating, particularly where the float is of the usual spherical form. There is a tendency, in other words, for the deposited layer to vary in thickness so that the resulting floats will not stand up under the pressures to which they are subjected when in use, and there ma even be actual holes left in the deposited s ell or the metal be so thin in places that holes promptly form as the result of handling or corrosion in use, thus rendering the floats permeable to a liquid.

We have discovered, however, that by the use of proper means, more particularly a foundation of special construction and superficial character and the employment of certain steps all as hereinafter fully described and particularly pointed out in the claims, we can make a float shell by electrodepositing copper or e uiv'alent metal on an internal hollow foun ation that will be superior both in the matter of strength, i. e., rigidity under pressure, and durability. The annexed drawing and the following description accordingly set forth in detail certain steps and means embodying the invention, such disclosed steps and means constituting, however, but one of various ways in which the principle of the invention may be used.

In saidannexed drawing Fig. 1 is a perspective view of the improved form of hollow foundation which we employ in our method; Fig. 2 is a central section through such foundation showing as assembled therewith the spud whereby the float when completed may be connected with suitable operating mechanism; Fig. 3 is a view similar to Fig. 2 but showing the electro-deposited layerof metal as surrounding the hollow foundation or core; Fig. 4 is a view similar to Fig. 3 but on a larger scale; and Figs. 5 and 6 are sectional views illustrating modifications.

The core 1, while shown in the several figures of the drawing as of approximately spherical form, may of course take on any the float, be of the particular type herein shown and described, such spud forming the subject-matter of a separate application filed by John Rowland Brown, one of the present inventors, viz, Ser. No. 505,524, filed October "5, 1921, patented Feb. 5, 1924, No. 1,482,882.

Said core 1 is preferably molded from pulp material, as for example, wood pulp or papier-mach, and is characterized by having its exterior surface closely and more or less uniformly dotted with small rounded protuberances 3. The thickness of the core shell may vary, but ordinarily such shell is not subjected to any great strains before being coated with metal and the latter is of course principally relied upon to give the finished article the necessary strength.

However, if desired, the core itself may be made of such thickness as tocontribute to the ri 'dity of such finished article toany desire degree. I

A core of the character just described, where made of such pulp material, may be most conveniently made by employing a process such as the Drake process, this process being characterized by the employment of a separable foraminous mold complementary to the exterior configuration of the article to be molded, in combination with means for injecting the pulpy fluid into such mold and expelling the fluid vehicle constituent of the material so as to leave only the solid constituent of the pulp adhering to the mold. The outer surfaces of articles made by this process necessarily take the form of the foraminous mold sections due to the fact that the material under the internal pressure employed is forced into and more or less through the openings in such mold sections which are ordinarily made of metal plates with closely spaced perforations constituting a fine mesh screen in effect. To secure the best results in our utilization of cores made by the aforesaid process, care should be taken to have the openings in the foraminous mold section of substantially uniform size and they should likewise be substantially uniformly spaced throughout the entire extent of the mold so that the resulting product, consisting of the core 1, as-

' shown in Fig. 1, will have its surface uniformly studded with tiny projections, the relative size of which is indicated by the sectional views of Figs. 2 and 3 which are drawn directly to scale for a spherical float having a diameter of 5 inches. In other words, allowing for a metal shell 1/64 inch thick to be deposited on said core, the outside diameter of the latter will be, as shown approximately 4 31/32 inches.

It should be stated at this point that other materials, such as celluloid and even paraffine, may be molded by well known methods to form cores having an exterior surface. possessing the characteristics just described, the only reason for preferring a core made of pulp material being the relative simplicity attending its manufacture and corresponding decreased cost, while of course such material, if sufliciently compacted in the mold, will form a core possessing a considerable degree of frigidity and strength as well as low specific gravity compared with its bulk. I,

Where the core is thus made of pulp material by a process such as the one described above the fibers in certain cases tend to project beyond the protuberances 3 like tiny hairs and require to be smoothed down before proceeding with the electrodepositionof the metal which forms the exterior shell of the float. To this end the molded core isgiven a coating either of melted parafline, swing, or a lacquer of the kind. hereinafter referred to. The 'surface may furthermore be polished to a certain extent after application of such coating, if desired, only a very thin coating being required in order to accomplish the desired result. Thereu on, the core is ready to receive its metal coatlng.

First, however, the laterally projecting flange 2 of the spud 2 is cemented to the open end of the core which is depressed around the aperture therein to form an annular recess 4 of the proper size and sha e to receive such flange. A solution of silicate of soda forms a satisfactory cement for use in this connection, the joint between the edge of the flange and the recess being filled flush so as to make a perfectly smooth surface and in addition such joint is sealed with a suitable lacquer, i. e., one imparting a smooth finish and at the same time capable of receiving and holding a coating of bronze or copper powder, or other material onto which the final metallic coating may be electrodeposited. Where a plain hollow sphere, or like article, is desired, without any spud such as hereinbefore described being attached thereto, a curved plate 7 (Fig. 5) may be substituted for the flange 2 of such spud, thus closing the opening in the core and cpnforming with the spherical surface thereof.

The core thus prepared and with the spud or its equivalent cemented in place, may thereupon be electroplated with copper, nickel or other suitable metal, in accordance with the well-established practice. We have found, however, that it is desirable to dust the exterior surface of such core with copper or bronze powder, rather than graphite,

before placing the same in the electrolytic bath and in order to insure the sticking of such powder to the surface, the latter may be desirably entirely coated with a lacquer of the kind just referred to, instead of using the latter merely around the joint between the spud flange 2 and recess 4. A cellulose ester, such as the nitrate or acetate dissolved in one or more of the known solvents therefor constitutes a very satisfactory lacquer for this purpose.

When placed in the electrolytic bath the multitude of tiny protuberances 3, despite their relatively minute size, seem to have the effect of insuring a uniformity of action over the entire surface of the shell so that the deposited metal builds up evenly everywhere instead of tending to become 10- calized as with the case of a core having a smooth exterior or one with projections of a more pronounced character and spaced further apart. As indicated in Figs. 3 and 4, the deposited layer 5 of metal preserves to a certain extent the irregularities of the exterior surface of the core, the protuberances III naeaaee 3 being reproduced in the form of somewhat flattened out protuberances 6.

Where it is desired to deposit an unusually thick coat of metal, in order to make the float or equivalent article of correspondinglg greater strength, it may be found desire is to stop the eposition of the metallic coat after a point has been reached where the surface can be turned or ground off to give a smooth efl'ect, without intersecting the protuberan'ces 3 of the core. Then a further deposit of metal is had directly on such smooth metallic surface. .This modification is illustrated in Fig. 6, where the base layer of metal 8 is shown as thus smoothed ofl, following which a second layer 9 has been deposited. It will be understood, of course, that no line of demarcation exists between the two layers, but as a result of the smoothing operation, the final surface will be substantially smooth, and the mottled appearance that otherwise persists will be avoided.

We have found, as the result of extensive tests, that. a float or other article fabricated in the manner just described presents for the amount of metal required far greater strength and rigidity than can be obtained by constructing an all metal float, using the same amount of metal. At the same time we are able to secure a uniformly tight, i. e., unpunctured shell even about the spud, which is in eflect integrally incorporated into such shell by the direct deposition thereon of metal at the same time that the body of the core is being coated. It should not be necessary to repeat that our improved process is not limited to the fabrication of floats of the kind specifically referred to herein, but is applicable to the making of floats of various shapes and sizes, as well as various articles ofsimilar character, irrespective of the particular use for which they may be intended.

Other forms may be employed embodying the features of our invention instead of the one here explained, change being made in the form or construction, provided the elements stated by any of the following claims or the equivalent of such stated elements be employed, whether produced by our preferred method or by others embodying steps equivalent to those stated in the following claims.

We therefore particularly point out and distinctly claim as our invention 1. In a method of making a float or like article, the steps which consist in first forming a hollow core of non-metallic material,

the exterior surface of said core being covered with closely spaced tiny protuberances, and then electroplating such core.

2. In a method of making a float or like article, .the steps which consist in first moulding a hollow core of plastic material,

the exterior surface of said core being cov' ered with closely spaced tin protuberances, and then electroplating suc core.

3. In a method of making a float or like article, the steps which consist in first moulding a hollow core of pulp material, the exterior surface of said core being covered with closely spaced tiny protuberances, and then electroplating such core.

4. In a method of making a float or like article, the steps which consist in first moulding a hollow core of pulp material, the exterior surface of said core being covered with closely spaced tiny protuberances, eliminating from such surface any projecting fibers, and then electroplatin said core.

5. In a method of making a oat or like article, the steps which consist in first moulding a hollow core of pulp material, the exterior surface of said core being covered with closely spaced tiny protuberances,coating such surface with a suitable lacquer, and then electroplating said core.

6. In a method of making a float or like article, the steps which consist in first moulding a hollow core of pulp material, the exterior surface of said core being covered with closely spaced tiny protuberances, coating such surfacewith a lacquer having a cellulosic base, and then electroplating said core.

7. In a method of making a float or like article, the steps which consist in first moulding a hollow core of pulp material, the exterior surface of said core being covered with closely spaced tiny protuberances,coating such surface with a lacquer having a cellulosic base, thereupon dusting such lacquered surface with a metallic powder, and then electroplating said core.

8. In a method of making a float or like article, the steps which consist in first moulding a hollow core of pulp material, the exterior surface of said core being 'covered with closely spaced tiny protuberances, then electroplating such core, smoothing ofl the surface of the electrodeposited layer, and thereupon electrodepositing a further layer.

9. In a method of making a float or like article, the steps which consist in first forming a hollow core of non-metallic material, said core having an aperture at one point in its wall, cementing a curved plate over such aperture, and then electroplating the whole. 10. As a new article of manufacture, a float for steam traps and the like, comprising a hollow core, the exterior surface of said core being formed with closely spaced tiny protuberances, and a metallic coat electro-deposited on said core and conforming with such protuberances.

11. As a new article of manufacture, a float for steam traps and the like, comprising a hollow core molded from plastic material, the exterior surface of said core being tilt lllld llld its

formed with closely spaced tiny rotubernnces, and a metallic coat electro eposited on said core and conforming with such protuberances.

12. As a new article of manufacture, a float for steam traps and the like, comprising a hollow core of molded pulp materlal, the exterior surface of said core being formed with closely spaced tiny rotuberances, and a metallic coat electroeposited on said core and conforming with such protuberances.

13. As a new article of manufacture, a hollow article for use as a fioat for steam I traps and the like, comprising a hollow core,

the exterior surface of sald core being formed with closely spaced tiny protuberances, and a metallic coat deposlted on said core and conforming with such protuberances. 4

14. As a new article of manufacture, a hollow article for use as a float for steam traps and the like, comprising a hollow core of plastic material, the exterior of said core being formed with closely spaced tiny rotuberances, and a metallic coat deposite on said core and conforming with said protuberances.

15. As a new article of manufacture, a hollow article for use as a float for steam traps and the like, comprising a hollow core of molded pulp material, the exterior of said core being formed with closely spaced tiny protuberances, and a metallic coat deposited on said core and conforming with such protuberances.

Signed by us, this 2nd day of February,

JOHN ROWLAND BROWN. JOHN G. MULLINNIX. 

